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Powder Coating builds around masked holes

We have a bracket that is 3/8" thick that we tap with several different sizes. Our problem is, even though we plug the holes with urethane type plugs, we get a build up of paint around the plug, which forces us to re-tap the holes. Is there any suggestions on different plugs or techniques that can save us this costly step.

Pete Schulte
Machine shop Mgr. - Audubon, Iowa, USA
2004

Pete, can you powder coat the parts first and then carefully drill and tap the holes? Many castings are now powder coated prior to machining to eliminate masking problems.

Roy Nuss
Trevose, Pennsylvania, USA
2004

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